Design of backdoor

AIM:

    To design back door of the car on sheet metal using the appropriate design and provided skin data by considering design parameters.

objective :

. To design a back doorof a car with an inner pannel ,outer panel ,and reinforcement for hinges ,gas stay ,wiper motor and latch.

. Theinner panel is subjected to the draft analysis ensure whether it is satisfying the deep drawing requirement for th tooling direction that is created in the design

. inner panel

. outer panel upper / lower

.Hinge reinforcement

.gas stay LH/RH

.wiper motor reinforcement

.latch reinforcement

Design consideration

 .Rear visibilities for safety and functionality

. support structure like hinges and gas stay/power lifter

.Rear crash regulation

.boot space

.mounts for wiper motor and lights

.strength criteria

.draft analysis

Design methodology:

Firstli we have to check if there are any surface irregularities are there ,then repair if by using a bridge curve and through curve mesh and sew it .

then we creat a sealing flange ,generally with the help of master sketch .we will design the panel with appropriate dimension .but here there is no master sketch,we designed by assumption.

Creation of tooling direction

Back door is going to be manufactured by deep drawing process has a tool which is core and die the core part follows the single straight specified place, this helps to reducing vibration and overall NVH(noise ,vibration and harness)

Then the sheet will be bend with the helped of another die to make the flanges in "L " shape.

inner panel:

inner panel is a component which is used for strengthen the door assembly and it is one of the most important components on which all accessories are mounted like hinges ,glass guide channel , molded trim ,latch etc.the possible method is the integration method in the integration method ,the part is stamped out of a single blank .This reduces the number of tools needed ,the assembly cost and eliminates any fit ability problem.

outer panel:

  The outer panel of the back door is similar to the other BIW components where it is the aesthetic part of vechicle .The coating  provided is multi stage which has the property of scratch resistance, rust prevention and smooth and attractive finishes .The outer panel also has the  provision for the tail. Lamp ,rear fog lamp and also has the provision for license plate mounting .most of the hatch back cars have the provisions for wiper motor

emboss and Reinforcement

with the distinctive cross section ,embosses are created .the embossed are used to increase the strength of the back door .while  designing  we should keep in mind that it should not be over strength .so we design to prefer the big embosses rather than small embosses.these embosses are used to despite the force sideways

Hinge embosses

The back door is a swinging commodity ,which swing with the help of hinges .this can be done by tentatively positioning the hinges axis we take a center point.Again we take another center point on the latch hole .take two points as a reference we draw  the circle . the circle is the latch tragitery and it has to be perpendicular .This can be achived  by moving the hinge axis back and forth  or by rotating the latch area.

wiper motor

hemming operation

Hemming is an mechanical joint design which is used for joining inner and outer closure panels as found indoors crash resistance the gap between the hemmed panels is filled with ahigh strength adhesive which also prevent from corrosion

conclusion

Thus the back door was designed and developed from the given styleing surface with essential reinforcement and embosses . to satisfy the manufacturing requirements draft analysis was also done on the inner panel